Method of forming edge for overstuffed furniture



Feb. 17, 1953 A. A. STANTON METHOD OF FORMING EDGE FOR OVERSTUFFED FURNITURE Filed Sept. 16, 1947 2 SHEETSSHEET l is \m any);

INVENTOR. ALLEN A STANTON ATTORNEY Feb. 17, 1953 A, A, STANTON 2,628,667

METHOD OF FORMING EDGE FOR OVERSTUFFED FURNITURE Filed Sept. 16, 1947 2 SHEETS-SHEET 2 INVENTOR ALLEN A STANTON ATTORNEY Patented Feb. 17, 1953 UNITED STATES PATENT OFFICE 'METHOD OF FORMING EDGE FOR OVERSTUFFED FURNITURE AllenA. Stanton, Seattle, Wash.

Application September 16, 1947, Serial No. 774,321

3 .Glaims.

This invention relates in general to themanufacturing of so-called overstuffed furniture, including davenports, couches, chairs and the like, in which a frame containing coil springs comprises the basic structure of a seat portion of the furniture and in which an inner covering is required to be secured over the sea-t frame as an intermediate manufacturing step before the final upholstery materials are applied thereto.

More specifically, this invention relates to the forming of an inner roll-or cushion strip along the top outside longitudinal edge of the wire spring frame of the seatporticn, preparatory to the final covering of the same.

It is the universal practice in the manufacturing of overstuffed. furniture of the type above indicated to provide some sort of cushioning strip over the top front edge of the spring for the seat-portion, and the reasons for this are obvious and. well known. However, the attaching of the cushion strip .or roll along this top edge of the spring frame has heretofore been a slow and tire manual task. This is customarily done by sewing the strip or roll in place using a long needle and heavytwine, and at least some amount of skill is necessaryso that the strip or roll will be held in place over the edge by the stitching so as to cover both the top and front surfaces of the heavy wire forming the longitudinal edge of the wire sprirr assembly. The needle frequently strikes against the edges of the coil springs or the edges of the longitudinal frame edge wire,

pressible nature of the strip or roll and to the arrangement of coil springs, securing wires, and edge wire, all of which are also necessary in the spring frame, these various attempts, to the best of my knowledge, have been unsatisfactory. he result is that the manual sewing of the strip or roll in place along the edge of the spring frame as above described, has continued to be the customady method employed.

The object of the present invention is to provide an improved method and means of attaching this cushioning strip or roll along the 1011- gitudinal edge of a spring frame, preparatory to applying the outer upholstery material, which method will eliminate the manual sewing of the strip or roll in place.

A further object ofthis invention is to provide an improvedmethod andmeansfor this purpose which will permit the use of thinvstapling wire instead. of the customary thread or twine in orderthat a more secure and more durable upholstery edge construction will be ob-. tained.

An additional object of this invention is to provide a simple and practical method and means.

for securing the cushioning strip or roll in place in which most of the work can be done mechanically and quickly and which will not require any exceptional amount of skill on the part of the operator.

The manner in which I have been able to .ob-

tain these objects, the steps employed .in,myim.-.

proved method, and the means which I have found successful in the carrying out of the same, will be briefly explained and described with reference to the accompanying drawings wherein;

Fig. l is a fragmentary sectional elevation showing a spring seat frame assembly before any. upholstering of the same;

Fig. 2 shows the same section with a burlap covering attached over the spring frame, illustrating the first step in my method;

Fig. 3 illustrates a cushioning roll resting along the edge of the frame in Fig. 2;

Fig. 4 shows the same cushioning roll temporarily held in position :by an extra flap or strip of burlap illustrating a, further step in my method;

Fig. 5 is a related fragmentary elevation drawn to a slightly larger scale, indicating thepositionof the anvil and plunger elements of a special stapling machine employed for the final Securin of the cushioning roll in place;

Fig. 6 is a sectional elevation, drawn to a smaller scale of the same cushioning roll and adjacent spring frame together with the head ofa stapling machine shown in elevation, illustrate ing the cushioning roll in the process of being secured in place by wire stapling; and

Fig. 7 is a fragmentary sectional elevation, drawn to the same scale as Fig. 5, showing the cushioning roll permanently secured as a result of the stapling operation.

Referring first to Fig. 1, the spring seat frame assembly, indicated in part in the drawings, is of the customary type used in overstuffed furniture and includes rows of coil springs, one such spring It being shown in the drawing. The coil springs are generally supported on metal or fabric strips H which in turn are secured to wooden base frame members, of which the front one 12 is shown in the drawings. Thesprings 1.0 are clamped err-otherwise. secured to vtie .wires. I33 rand to each other at their upper most loops, and the outer row of springs have their top loops also secured to the front edge wire H of the spring frame assembly. My invention is concerned with the problem of securing a cushioning strip or roll along the top and front of this edge wire I4.

It is common procedure in upholstering a spring frame, first to place an inner covering of coarse material such as burlap, over the springs. I follow this practice also, as the first step in my method, except that in addition, I first sew an extra strip or flap I6 of the burlap (Fig. 2) to the burlap or other material which is to serve as the inner covering I 5 of the spring, and then attach this inner covering |5 to the wooden base frame, for example, by tacks l8, illustrated in Fig. 2. The sewing stitch line I! on which the extra strip or flap i6 is sewed to the main piece I5, is arranged so as to be parallel to the edge wire l4 and at a distance of a few inches in from the edge, the distance in from the edge depending upon the size of the cushionlng strip or roll which it is desired to place over the edge wire ll.

When the inner cover I5 is secured in place with the extra flap IE on top as shown in Fig. 2, I place the cushioning strip or roll l9 above the edge wire approximately in the position illustrated in Fig. 3. Then, with the roll IS in this position, I bring the extra flap it back over the top of the roll l9 and pull the free end of the flap I6 down over the wooden frame member i2 temporarily securing this end to the frame member 2 by a few tacks (indicated at in Fig. 4) or other similar means. The roll I9 is now ready and in position for the final and important step in my method, namely the securing of the roll firmly and permanently in place on the edge wire. For this purpose I employ a special stapling machine, the head portion of which, 2|, is shown in Fig. 6.

My special stapling machine in most respects is similar to the common, well known, motordriven type of stapling machine, and the head 2| has a plunger 22, to which wire is fed from a spool 23, and includes means (not shown) for cutting the wire into staple lengths. The machine is driven by a motor M to which a drive shaft 24 is connected by suitable belt and pulleys. The plunger 22 operates in alignment with I an opposed stationary anvil 25 which is rigidly secured to one of the jaws 26 of the head 2| so that the two ends of each staple will be bent over inwardly and towards each other as the staple is forced into contact with the anvil 25 upon operation of the plunger. All this mechanism is old and common to stapling machines in general and, therefore, need not be further described. A suitable manual control or foot pedal control (not shown) is provided for the motor M so that operation of the machine can be started and stopped by the operator as desired.

However, the special stapling machine which I have found necessary to develop for the carrying out of my method differs from the ordinary stapling machine in two particulars. First, the head 2| is so mounted that the two jaws 25 and 21, instead of being horizontal, will slope obliquely and preferably at an angle of approximately with the horizontal, as illustrated in Fig. 6. Second, the anvil 25 is arranged above the plunger 22 instead of below it, as customary with ordinary stapling machines, and the reason for this will be explained later.

desired angle and heighth with respect to the work I support the head 2| on an adjustable arm 28 which in turn is slidably mounted in a suitable standard, the upper portion of the standard being indicated at 29 in Fig. 6. This arm 28 can be raised or lowered in the supporting standard and maintained at any desired heighth by a clamp screw indicated at 30. The upper end 3| of the arm 28 is inclined at an angle with respect to the main vertical portion and the head 2| is mounted on this upper end 3|. The head 2| could be rigidly mounted on this upper end 3|, but I prefer to mount the head in such a way as to have the angularity of its position adjustable. Thus, as indicated in Fig. 6, the head 2| is pivoted to the upper portion 3| of the arm at 32 and a clamping nut 33, carried by the upper arm portion and engaging a slot in the head 2|, clamps the head rigidly to the upper arm portion 3| at -the desired angle.

The spring frame on which the cushioning strip or roll, as previously described, is to be secured, is placed on a truck or similar simple conveyor so that the entire frame can be moved along with respect to the stapling machine, and the machine head 2| is so adjusted with respect to the work that the machine and the spring frame will be substantially in the relative positions illustrated in Fig. 6.

The manner in which the stapling machine, when so arranged, will function to secure the cushioning roll in place on the spring frame, can now be described more clearly with reference to Figs. 5 and 7. With the extra flap l6 extending over the top of roll l9 and temporarily fastened down to the front wooden base member as previously described with reference to Fig. 4, one end of the spring frame and the stapling machine are brought into the relative positions shown in Fig. 5. In such position the stationary anvil 25 of the machine is caused to press against the side of the roll l9 and at the same time to press downwardly on the flap |6 above the line of sewing IT. The bottom edges of the anvil 25 are made smooth or rounded so that when the frame is pushed along longitudinally the flap l6 will slide along under the anvil while the anvil presses against the flap I6 without danger of the flap catching on the anvil. With the anvil 25 and the plunger 22 positioned as shown in Fig. 5 with respect to the spring frame and the roll I9, the machine is then operated while the spring frame and roll are moved along longitudinally. At each operation of the plunger 22, the portion of the flap I6 engaged by the plunger is pushed obliquely upwardly and inwardly while the plunger thrusts a staple through the thicknesses of the intervening burlap and the staple strikes against the anvil 25 and has its ends turned inwardly. This thrusting of the flap |6 pulls the flap more tightly over the roll I9 and compresses the roll I 9 slightly into the position shown in Fig. 7. The pressure of the anvil 25 against the flap l6 and roll l9, as illustrated in Fig. 5, aids in preventing the resulting pull on the flap l6 from tearing the flap loose along the sew line H, and I have found that unless the anvil exerts some constant pressure against the flap l6 and roll IS, the flap |6 will be pulled loose, since a coarse material such as burlap is used, and the staple driven in by the plunger will miss the upper end of the flap I6 and thus fail to provide a suitable hold for the roll IS. The extra pull on the flap |6 which occurs with the movement of the plunger, on the other hand,

In order to have the head 2| arranged at the may, and often does, cause the lower end of the flap [6 to be pulled loose from its temporary fastening on the base board l2 of the spring frame. but this does not matter since the lower end of the flap does not serve any other further purpose after the stapling is done.

As the spring frame is moved along under the machine and the machine is operating, a series of staples such as the staple 35 shown in Fig. 7, will be set in place and these staples will firmly secure the roll 19 in the desired position on the frame. During the stapling operation a few of the staples will, of course, strike against the top coils of some of the springs 10. However, at most this results only in the loss of a few staples and does not cause any difficulties or any injury to the machine or frame, and does not retard the speed with which stapling, and thus the final securing of the roll 19 in place, is performed. When the stapling has been completed for the length of the roll and thus the roll I9 is secured, in the manner and in the position illustrated in Fig. 7, the final outer upholstery covering and padding are then applied in the usual manner. However, this need not be described since this final step is well known and does not constitute any part of my present invention.

From this brief description it .will be apparent that the cushioning roll or strip i9 is secured in place on the spring frame, through my method,

much more firmly and permanently than is posa stapling for ordinary sewing in attaching such 1 cushioning rolls in place, these did not prove successful because the stapling machine was not properly arranged and designed and because it was considered necessary to have the staples pass through the roll itself. After I had made a number of unsuccessful attempts to hold the Work at different angles with respect to the stapling machine, having usual horizontal jaws and the anvil located below the plunger, 3; finally discovered not only that the extra flap of burlap for holding the cushioning roll in proper position was desirable, but that even with this extra flap the stapling could not satsifactorily be done unless the customary position of the plunger and anvil in the stapling machine were reversed and the anvil arranged so as to press down on the work while the staples were thrust into position.

It would be possible Within the scope of my invention to have the flap I6 arranged differently or even to have the inner covering sheet l5 extend over the roll l9, but I consider the arrangement as illustrated and described to be the best manner of carrying my invention into practice.

I claim:

1. In the manufacture of overstuffed furniture having an inner spring frame of the character described, the improved method of Govering the outer edge wire of said spring frame, which method includes providing an inner covering of material for said frame and securing said covering over said frame, attaching a flap to said covering along a line on the top of said frame near and substantially parallel to said edge wire, arranging a cushioning roll above said outer edge wire and said inner covering so that said roll will extend along said edge wire with the outer face of said roll overhanging said edge wire, pulling said outer fiap over said cushioning roll and temporarily securing the free end of said flap below said edge wire and roll, and stitching obliquely through the top and front faces of said outer flap and said covering material along a line adjacent the inner edge of said roll, by means of staples passed obliquely under said edge wire, while holding said roll firmly against inward movement on the top of said frame during said stitching.

2. In the manufacture of overstuffed fumiture having an inner spring frame of the character described, the improved method of covering the outer edge wire of said spring frame, which method includes arranging a cushioning roll along the top of said outer edge wire so that said roll will extend along said edge wire with the outer face of said roll overhanging said edge wire, securing a covering of material in place over the top of said frame and roll with said covering fastened down over the outer face of said roll and frame, and stitching obliquely through the top and front faces of said covering material, along a line adjacent the inner edge of said roll, by means of staples passed obliquely under said edge wire, while holding said roll firmly against inward movement on the top of said frame during said stitching.

3. In the manufacture of overstuffed furniture having an inner spring frame of the character described, the improved method of covering the outer edge wire of said spring frame, which method comprises providing an inner fabric covering for said frame, stitching an outer flap on said covering, securing said covering over the top of said frame and over the outer face below said outer edge wire so that the stitch line of said flap will be on the top of said frame near and substantially parallel to said edge wire, arranging a cushioning roll above said outer edge wire and said inner covering so that said roll will extend along said edge wire with the outer face of said roll overhanging said edge wire and the outer face of said covered frame below said wire, pulling said outer flap over said cushioning roll and temporarily securing the free end of said flap near the bottom of the outer face of said frame below said edge wire, and stitching obliquely through the top and front faces of said outer flap and said covering fabric along a line adjacent the inner edge of said roll, by means of staples passed obliquely under said edge wire, while holding said roll firmly against inward movement on the top of said frame during said stitching.

ALLEN A. STANTON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,781,086 Smith Nov. 11, 1930 1,888,357 Oldham Nov. 22, 1932 1,894,831 Phenix June 17, 1933 2,047,695 Lofman July 14, 1936 2,360,115 Droll Oct. 10, 1944 

